Connection device for vehicle equipped with a temperature sensor

ABSTRACT

A connection device for electrical connection of a vehicle to a charging cord provided with a charging socket includes a housing, a power contact disposed within the housing, and a printed circuit board mounted in the housing having a first face provided with a first metal pad which is compressed between the printed circuit board and a surface of the power contact, and a second face provided with a first temperature sensor which is arranged opposite the first metal pad. A method of electrical connection of a vehicle to a charging cord provided with a charging socket is also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.17/287,989, filed on Oct. 22, 2019, which was a National StageApplication of International Patent Application No. PCT/IB2019/059002,which claimed the benefit of French Patent Application No. 1859762 filedon Oct. 23, 2018, the content of each of which is hereby incorporatedherein by reference in its entirety.

This patent application is directed to a connection device for theelectrical connection of a vehicle to a charging cord, more particularlyto a connection device including a connection base provided with atleast two power contacts intended for recharging the batteries of anelectric or hybrid vehicle.

BACKGROUND

To allow a reduced charging time, it is planned to increase the electriccharging power, which requires increasing the charging voltage and thecurrent intensity. It is planned to increase the intensity of theelectric current from 125 to 200 Amperes currently, for direct currentcharging, to 500 Amperes.

The significant increase in the intensity of the current brings greaterrisks of overheating, which can cause fire to start. It is thereforenecessary to monitor any rise in temperature, in particular at the levelof the power contacts, by means of temperature sensors.

SUMMARY

According to one or more aspects of the present disclosure, a connectiondevice for the electrical connection of a vehicle to a charging cord isprovided with a charging socket. The connection device includes ahousing in which are mounted to the at least first and second powercontacts. Each power contact including a front section which extends ina connection base at the front of the housing and a rear section whichextends in a rear part of the housing, in a direction substantiallyparallel to a direction of connection of the charging socket. Theconnection base is provided to allow the connection of an additionalcharging socket. Advantageously, at least one printed circuit board ismounted in the rear part of the housing. The printed circuit boardextends in a plane substantially parallel to the direction ofconnection. The printed circuit board includes a first face providedwith a first metal pad which is compressed between the printed circuitboard and an axial surface of the rear section of the first powercontact and a second face provided with a first temperature sensor whichis arranged opposite the first metal pad, so as to allow rapid detectionof any abnormal rise in temperature at the level of the first powercontact.

According to another advantageous characteristic, the housing has in itsrear part two grooves substantially parallel to the direction ofconnection which receive opposite edges of the printed circuit board.

According to another advantageous characteristic, the housing has in itsrear part a retaining wall which is substantially parallel to thedirection of connection, and which is in contact with the axial surfaceof the rear section of the first power contact, in an area of the firstcontact of power diametrically opposite to the first metal pad.

According to another advantageous characteristic, the retaining wallincludes a portion of cylindrical surface which matches the axialsurface of the rear section with which the retaining wall is in contact.

According to another advantageous characteristic, the printed circuitboard has on its first face a second metal pad which is compressedbetween the printed circuit board and an axial surface of the rearsection of the second power contact, and on its second face a secondsensor temperature which is arranged opposite the second metal pad.

According to another advantageous characteristic, the first and secondtemperature sensors are electronic components mounted on the surface andsoldered to the second face of the printed circuit board.

According to another advantageous characteristic, the metal pad isproduced with silver or tin which is deposited on the first side of theprinted circuit board.

According to another advantageous characteristic, the layer of silver ortin forming each metal pad is deposited on a copper surface previouslyarranged on the first face of the printed circuit board.

DESCRIPTION OF THE DRAWINGS

Other characteristics, objects and advantages of the invention willappear on reading the detailed description which follows, and withreference to the appended drawings, given by way of non-limiting exampleand in which:

FIG. 1 is a general perspective view which represents a connectiondevice for the connection of a charging socket;

FIG. 2 is a perspective view which represents the rear part of theconnection device of FIG. 1 equipped with temperature sensors accordingto an embodiment of the invention;

FIG. 3 is a top view in the direction F3 which represents the rear partof the connection device of FIG. 2 ; and

FIG. 4 is a perspective view which represents the printed circuit boardprovided with metal pads which equips the connection device according tothe invention.

DETAILED DESCRIPTION

FIG. 1 represents a connection device 10 for the electrical connectionof a vehicle (not shown) to a charging cord 12 provided with a chargingsocket 14. The connection device 10 is itself electrically connected toat least a battery 16 on board the vehicle and intended to be chargedvia the charging socket 14.

The connection device 10 includes a housing 18 in which are mounted afirst and a second power contacts 20, 22. The housing 18 includes, in afront wall 24, that is to say on the side of the charging socket 14, abase of connection 26 which is configured to additionally receive thecharging socket 14 in order to establish an electrical connectionbetween the charging cord 12 and the battery 16.

In the following description, use will be made, without limitation, ofan orientation from the front towards the rear in a direction ofconnection A1 of the charging socket 14 in the connection base 26. Inaddition, identical elements or similar may be designated by the samereferences.

As can be seen more particularly in FIG. 2 , each power contact 20, 22has the shape of a generally cylindrical rod which has a front section28 extending in the connection base 26, at the front of the housing 18,and a rear section 30 extending in a rear part 32 of the housing 18. Therear part 32 of the housing 18 has a rear wall 34 which is substantiallyperpendicular to the direction of connection A1. The rear section 30 ofeach contact power 20, 22 extends beyond the rear wall 34 towards therear to allow electrical connection to the battery 16. A connector 36,connected to the battery 16 by cables 38, is provided to be mountedagainst the rear part 32 of the housing 18 by establishing electricalcontact with the rear section 30 of each power contact 20, 22.

According to an embodiment of the invention, illustrated moreparticularly by FIGS. 2, 3, and 4 , a printed circuit board 40, providedwith first and second temperature sensors 42, 44, is mounted in the rearpart 32 of the housing 18 so that the printed circuit board 40 extendsin a plane substantially parallel to the direction of connection A1.More specifically, in the present nonlimiting example, the printedcircuit board 40 has here the shape of a rectangular plate whose widthextends parallel to the direction of connection A1 and whose lengthextends perpendicular to the direction of connection A1, from the firstpower contact 20 to the second power contact 22. As a variant, othermounting orientations of the printed circuit board 40 can make itpossible to obtain a printed circuit board 40 which extends in a planesubstantially parallel to the branching direction A1. The printedcircuit board 40 has a first face 46 provided with first and secondmetal pads 48, 50 which are provided to be pressed against the externalcylindrical wall 52 of the associated power contact 20, 22. The firstand second temperature sensors 42, 44 are mounted on a second face 54 ofthe printed circuit board 40, on the side opposite to the metal pads 48,50. Advantageously, the first temperature sensor 42 is arrangedopposite. -vis the first metal pad 48 and the second temperature sensor44 is arranged opposite the second metal pad 50.

The printed circuit board 40 has conductive traces 53 which allow theelectrical connection of the temperature sensors 42, 44 to a connectionarea 55 where electrical wires 56 are connected. The electrical wires 56allow the temperature information supplied by the temperature sensors42, 44 to an associated electronic control unit 58. The electroniccontrol unit 58 can thus detect, via the temperature sensors 42, 44, anabnormal rise in temperature at the level of the power contacts andtrigger a trip to safety of the connection device 10.

Advantageously, the metal pads 48, 50 are produced by depositing metalaccording to technologies for manufacturing a printed circuit board, forexample by depositing a layer of silver or a layer of tin on the firstface 46 of the printed circuit board 40. More particularly, the printedcircuit board 40 is provided with a copper layer which serves to formthe conductive traces 53 for the electrical connection of thecomponents, such as the temperature sensors 42, 44 mounted on theprinted circuit board 40. Copper surfaces, the shape of which generallycorresponds to the shape of the metal pads, are therefore arranged onthe first face 46 of the printed circuit board 40 and a layer of silveror a layer of tin are deposited, by a suitable method, on these coppersurfaces so as to form the metal pads 48, 50. The metal pads 48, 50 thusform metallic platelets, metallic studs, or metallic pads.

The material forming the metal pads 48, 50 is chosen to be relativelysoft so that the external surface of the metal pad 48, 50 can deformwhen it is pressed against the external cylindrical wall 52 of theassociated power contact 20, 22. The metal pads 48, 50 have a sufficientthickness to allow slight deformation of the material on the surface ofeach metal pad 48, 50, where the power contact 20, 22 comes to bear.This makes it possible to maximize the contact surface between eachmetal pad 48, 50 and the associated power contact 20, 22 to ensureoptimal thermal conductivity between the two elements. Advantageously,each metal pad 48, 50 has a thickness, perpendicular to the printedcircuit board 40 of between 1 and 50 μm.

The material chosen for the metal pads 48, 50 is also chosen for itsqualities of thermal conduction to the temperature sensors 42, 44, forits ability to withstand the high electrical voltages passing throughthe power contacts 20, 22, and for its reasonable cost. Alternatively,the metal pads 48, 50 can be made of another material which is easy todeposit on the printed circuit board 40 and which offers similarqualities and properties.

The arrangement of the metal pads 48, 50 relative to the power contacts20, 22 must make it possible to avoid as much as possible the presenceof air between these two elements, which penalizes thermal conductiontowards the temperature sensors 42, 44.

According to the embodiment shown here, the metal pads 48, 50 are ofrectangular or square shape. Alternatively, they could be of differentshapes, for example round or oval.

Advantageously, the temperature sensors 42, 44 are electronic componentsfor surface mounting (SMC or “Surface Mount Component”). They aresoldered directly to the second face 54 of the printed circuit board 40.The mounting of the temperature sensors 42, 44 on the face of theprinted circuit board 40 opposite the power contacts 20, 22 makes itpossible to provide protection. temperature sensors 42, 44 against highvoltages passing through the power contacts 20, 22, the substrate of theprinted circuit board 40 acting as a protective barrier.

According to the embodiment shown, the rear part 32 of the housing 18has two grooves 60, 62 substantially parallel to the direction ofconnection A1 which receive opposite edges 64, 66 of the printed circuitboard 40. Thus, the printed circuit board 40 can be mounted on the rearwall 34 by sliding in the grooves 60, 62, from rear to front in thedirection of connection A1.

According to the embodiment shown, the rear part 32 of the housing 18includes a first and a second retaining wall 68, 70 which aresubstantially parallel to the direction of connection A1, and which arein contact with the axial surface of the rear section 30 respectively ofthe first power contact 20 and the second power contact 22. Eachretaining wall 68, 70 is in contact with the power contact 20, 22associated on the side opposite to the associated metal pad 48, 50.Advantageously, each retaining wall 68, 70 includes a portion ofcylindrical surface 72 which matches the axial surface, or externalcylindrical wall, of the rear section 30 with which the retaining wall68, 70 is in contact. The positioning of the retaining wall 68, 70 withrespect to the grooves 60, 62 and with respect to the thickness of theprinted circuit board 40 is provided to ensure a slight pressure of therear section 30 of each power contact 20, 22 against the metal pad 48,50 associated when all the elements are mounted together. This resultsin a forced mounting of the power contacts 20, 22 between the retainingwalls 68, 70 and the metal pads 48, 50, and/or a forced mounting of theprinted circuit board 40 in the grooves 60, 62 This ensures optimalcontact between the power contacts 20, 22 and the metal pads 48, 50.This optimal contact ensures optimal thermal conduction from the powercontact 20, 22 to the temperature sensor 42, 44 associated, through themetal pad 48, 50 and through the thickness of the printed circuit board40.

In the embodiment shown, the retaining walls 68, 70 and the grooves 60,62 are produced integrally by injection of plastic material with therear wall 34. Each groove 60, 62 is formed in a portion of wall whichcomes extend the retaining wall 68, 70 associated opposite.

The embodiment shown corresponds to a connection device 10 for aconnection base 26 with two power contacts 20, 22. Of course, theinvention also applies to connection bases 26 including more than twopower contacts 20, 22.

LIST OF REFERENCE NUMBERS

-   -   10 connection device    -   12 charging cord    -   14 charging    -   16 battery    -   18 case    -   20 first power contact    -   22 second power contact    -   24 front wall    -   26 connection base    -   28 front section    -   30 rear section    -   32 rear section    -   34 rear wall    -   36 connector    -   38 cables    -   40 printed circuit board    -   42 first temperature sensor    -   44 second temperature sensor    -   46 first side    -   48 first metal pad    -   50 second metal pad    -   52 external cylindrical wall    -   53 conductive traces    -   54 second side    -   56 electric wires    -   58 electronic control unit    -   60 first groove    -   62 second groove    -   64 first edge    -   66 second edge    -   68 first retaining wall    -   70 second retaining wall    -   72 portion of cylindrical surface

1. A connection device for electrical connection of a vehicle to acharging cord provided with a charging socket, the connection devicecomprising: a housing; a power contact disposed within the housing; anda printed circuit board mounted in the housing having a first faceprovided with a first metal pad which is compressed between the printedcircuit board and a surface of the power contact, and a second faceprovided with a first temperature sensor which is arranged opposite thefirst metal pad.
 2. The connection device according to claim 1, whereina connection base is provided to allow connection of an additionalcharging socket.
 3. The connection device according to claim 1, whereinthe housing has two grooves arranged substantially parallel to adirection of connection which receive opposite edges of the printedcircuit board.
 4. The connection device according to claim 1, whereinthe housing has a retaining wall which is substantially parallel to adirection of connection, and which is in contact with the surface of thepower contact in an area of the power contact located diametricallyopposite to the first metal pad.
 5. The connection device according toclaim 4, wherein the retaining wall comprises a cylindrical surfaceportion which matches the surface of the power contact with which theretaining wall is in contact.
 6. The connection device according toclaim 1, wherein the printed circuit board has a second metal pad on itsfirst face which is compressed between the printed circuit board and asurface of a rear section of a second power contact and a secondtemperature sensor on its second face which is arranged opposite of thesecond metal pad.
 7. The connection device according to claim 6, whereinthe first and second temperature sensors are electronic componentsmounted on the surface of the printed circuit board and welded to thesecond face of the printed circuit board.
 8. The connection deviceaccording to claim 1, wherein the metal pad is produced with a layer ofsilver which is deposited on the first face of the printed circuitboard.
 9. The connection device according to claim 8, wherein the layerof silver forming the metal pad is deposited on a copper surfacepreviously arranged on the first face of the printed circuit board. 10.The connection device according to claim 1, wherein the metal pad isproduced with a layer of tin which is deposited on the first face of theprinted circuit board.
 11. The connection device according to claim 10,wherein the layer of tin forming the metal pad is deposited on a coppersurface previously arranged on the first face of the printed circuitboard.
 12. The connection device according to claim 1, wherein the powercontact has a front section disposed in a front part of the housing anda rear section disposed in a rear part of the housing.
 13. Theconnection device according to claim 12, wherein the printed circuitboard is mounted in the rear part of the housing.
 14. The connectiondevice according to claim 12, wherein the first metal pad is compressedbetween the printed circuit board and a surface of the rear section ofthe power contact.
 15. A method of electrical connection of a vehicle toa charging cord provided with a charging socket, comprising: disposing apower contact disposed within a housing; and mounting a printed circuitboard in the housing, wherein a first face of the printed circuit boardis provided with a first metal pad which is compressed between theprinted circuit board and a surface of the power contact, and a secondface of the printed circuit board is provided with a first temperaturesensor which is arranged opposite the first metal pad so as to allowrapid detection of any abnormal temperature rise at the power contact.16. The method according to claim 15, wherein the power contact is afirst power contact and wherein the method further comprises: disposinga second power contact disposed within the housing, wherein each powercontact has a front section disposed in a front part of the housingwhich extends in a connection base and a rear section disposed in a rearpart of the housing which extends in a direction substantially parallelto a direction of connection of the charging socket.
 17. The methodaccording to claim 16, wherein the connection base allows the connectionof an additional charging socket.
 18. The method according to claim 16,wherein the first face of the printed circuit board is provided with asecond metal pad which is compressed between the printed circuit boardand an axial surface of the rear section of the second power contact andthe second face of the printed circuit board is provided with a secondtemperature sensor which is arranged opposite the second metal pad, soas to allow rapid detection of any abnormal temperature rise at thesecond power contact.
 19. The method according to claim 15, wherein theprinted circuit board extends in a plane substantially parallel to adirection of connection.
 20. The method according to claim 15, furthercomprising: inserting opposite edges of the printed circuit board withingrooves defined by the housing that extend substantially parallel to adirection of connection.